Patented Gear Technology, smaller lighter and more efficient

1. Patented Gear Technology
• Ikona technology originates from Russian (Ukrainian)
military developments between 1986 and 1991 -
purchased by Ikona in 1992
• US Patent # 5,505,668 granted on April 06, 1996,
covering the “Ikona tooth-form”
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2. Patented Gear Technology
The key factor
Ikona Gear tooth form vs. Involute (Traditional) tooth form
Ikona Gear tooth form enables
High Contact Ratio and Zero Backlash
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3. Patented Gear Technology
Resulting Advantages:
High Gear Contact Ratio
• Increased gear strength and surface durability
• Smaller and lighter gears
• Lower noise and vibration levels
• Increased shock resistance
Tooth Difference as Low as 1
• High single-stage speed reduction ratios
(450, 260, 200, 80, 60, 30, 20 : 1)
• Reduced number of components, length and
weight of the unit.
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4. Patented Gear Technology
Resulting Advantages:
Zero Clearance and Minimal Torsional Backlash
• Lower noise and vibration levels
• Increased gear life
• Accurate positioning and repeatability
Flexible Manufacturing Methods
• Using traditional gear manufacturing
and verification processes
• Using variety of materials: steels, nonferrous alloys,
cast irons, powder-metallurgy and plastics
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5. Application-specific
Design
- Wind Energy
Blade Pitching and Yaw
Drive
•High contact ratios allow
gearing to withstand higher Blade pitching
(1)
loading conditions reducing
maintenance concerns Gearbox
•Has potential to decrease the
size and weight of gearing
allowing for a more compact
design
•Increased response time, and Yaw drive
allow for more precise and
repeatable positioning of blade
and nacelle
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6. Application-specific
Design
- Wind Energy
Main Drive Gearbox
•High contact ratios allow gearing
to withstand higher loading
conditions and reduce vibrations; Blade pitching
(1)
should lower maintenance
Gearbox
•High gear speed ratios allow for
less required gearing; should
reduce the size making it easier
to install and maintain
•Minimal to zero backlash
increases gear life, and lowers
noise level Yaw drive
•Ease in manufacturing gearing
should help in alleviating supply
chain issues
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7. Application-specific
Design
- Pitch Drive
Pitch Drive
• Enclosed and integrated with the
structure
• Incorporates: motor, gear drive,
bearings, resolver, manual over-
drive, limit switches, hard stops
• No external hardware, cables
• Lubricated
• Similar unit met appropriate
Defense Standards (MIL-STD)
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8. Application-specific
Design
- Pitch Drive
“Blade side”
Manual over-drive,
covered (opt.)
Motor
+ primary reduction (opt.)
+ brake
Resolver
(Orientation sensor)
Base (stationary)
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9. Application-specific
Design
- Pitch Drive
Large hole at the center of the Maintenance door
drive, could be over 10 inches in could be added
diameter, to provide an opening for
Lubrication ports
routing electrical cables
(can be extended for
direct outside access)
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10. Application-specific
Design
- Pitch Drive
Rotating components run in
sealed lubricated environment
Ikona gears enable high final
reduction ratio.
2-3 pinion design to optimize
bearing loads
Thin section angular contact ball bearings
react thrust loads, overturning moment and gearing loads
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11. Application-specific
Design
- Pitch Drive
Limit switches
(±90° here)
Resolver (Orientation
sensor)
Switch trigger
Hard Stop
(2 positions)
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12. Application-specific
Design
- Communication
Satellite Antenna Pedestal
(Elevation and Azimuth Drives)
• High positioning accuracy,
torsional backlash of the whole
system 0.45 mrad at 45 mph
winds
• High rigidity, torsional stiffness of
the pedestal 11,000,000 in-lb/rad
at 45 mph winds
• Total reduction ratio 2,600:1, for
each axis. High single stage gear
reduction ratio 260:1
• Fully operational up to 65 mph
winds and 1/2” of ice, and
survives over 75 mph winds
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